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Abstract:

A LED lamp with adjustable beam direction includes a housing, a lamp base
attached to one end of the housing for insertion into a lamp socket, a
heatsink shaft mounted within the housing, a LED attached to one end of
the heatsink shaft, a parabolic or elliptical or multi-facet reflector
having a light output front opening and an asymmetric elliptical shaped
rear opening, a first actuator for rotating the reflector about the LED,
and a second actuator for tilting the reflector about the LED.

Claims:

1. A LED lamp with adjustable beam direction, the lamp comprising: (a) a
housing; (b) a lamp base attached to one end of the housing for insertion
into a lamp socket; (c) a heatsink shaft mounted within the housing which
serves as a heatsink; (d) a LED attached to one end of the heatsink
shaft; (e) a reflector comprising a light output front opening and an
asymmetric elliptical shaped rear opening, the LED being disposed
proximate to the rear opening; (f) a first actuator for rotating the
reflector about the LED; and (g) a second actuator for tilting the
reflector about the LED.

2. The lamp as claimed in claim 1, wherein the first actuator comprises:
(a) a gear rotatable about the heatsink shaft; (b) two arms comprising
two ends fixedly connected to the gear and two opposite ends pivotably
connected to a rear surface of the reflector by two pivot joints
respectively; and (c) a pan motor for rotating the gear and in turn
rotating the reflector about a central longitudinal axis of the heatsink
shaft.

3. The lamp as claimed in claim 2, wherein the second actuator comprises:
(a) a collar mounted around the heatsink shaft and movable along two
columns connected to the housing and oriented generally parallel to the
heatsink shaft, the collar comprising external threads and an inwardly
and radially extending annular member; (b) a collar-engaging member
comprising a proximal end attached to the reflector and a distal end
slidably engaged with the annular member; (c) a cup gear comprising
internal threads meshed with the external threads of the collar; and (d)
a tilt motor for rotating the cup gear, thereby driving the collar along
the two columns, moving the distal end of the collar-engaging member
radially relative to the annular member, and tilting the reflector about
a pivot axis defined by the two pivot joints.

4. A LED light reflecting device comprising: (a) a housing; (b) a LED
attached to the housing; (c) a reflector comprising a light output front
opening and a rear opening, the reflector being rotatably and tiltably
coupled to the housing with the LED disposed proximate to the rear
opening; (d) a first actuator for rotating the reflector about the LED;
and (e) a second actuator for tilting the reflector about the LED.

5. The LED light reflecting device as claimed in claim 4, further
comprising a heatsink shaft mounted within the housing, and at least part
of the housing serving as a heatsink.

6. The LED light reflecting device as claimed in claim 4, wherein the
rear opening is asymmetric shaped.

7. The LED light reflecting device as claimed in claim 4, wherein the
rear opening is defined by a parabolic half and a semi-circle half.

8. The LED light reflecting device as claimed in claim 4, wherein the
reflector comprises a parabolic reflector or an elliptical reflector or a
multi-facet reflector.

9. The LED light reflecting device as claimed in claim 4, further
comprising a plurality of sensors for sensing the pan and tilt motions of
the reflector.

10. The LED light reflecting device as claimed in claim 5, wherein the
first actuator comprises: (a) a gear rotatable about the heatsink shaft;
(b) two arms comprising two ends fixedly connected to the gear and two
opposite ends pivotably connected to a rear surface of the reflector by
two pivot joints; and (c) a pan motor for rotating the gear and in turn
rotating the reflector about a central longitudinal axis of the heatsink
shaft.

11. The LED light reflecting device as claimed in claim 10, wherein the
second actuator comprises: (a) a collar mounted around the heatsink shaft
and movable along at least one column connected to the housing and
oriented generally parallel to the heatsink shaft, the collar comprising
external threads and an inwardly and radially extending annular member;
(b) a collar-engaging member comprising a proximal end attached to the
reflector and a distal end slidably engaged with the annular member; (c)
a cup gear comprising internal threads meshed with the external threads
of the collar; and (d) a tilt motor for rotating the cup gear, thereby
driving the collar along the at least one column, and moving the distal
end of the collar-engaging member radially relative to the annular
member, and tilting the reflector about a pivot axis defined by the two
pivot joints.

12. The LED light reflecting device as claimed in claim 10, wherein the
two arms are spaced 180 degrees apart on the reflector.

13. The LED light reflecting device as claimed in claim 10, further
comprising a link gear coupling between the motor and the gear rotating
about the heatsink shaft.

14. The LED light reflecting device as claimed in claim 11, wherein the
collar is mounted around the heatsink shaft and movable along two columns
connected to the housing.

15. The LED light reflecting device as claimed in claim 11, wherein the
annular member is an inwardly facing and radially extending annular
groove.

16. The LED light reflecting device as claimed in claim 11, wherein the
annular member comprises an inwardly facing and radially extending
annular ring.

17. The LED light reflecting device as claimed in claim 15, wherein the
collar-engaging member comprises a stylus, and the stylus comprises an
enlarged head movable within the annular groove.

18. The LED light reflecting device as claimed in claim 15, wherein the
collar-engaging member comprises a pair of coaxial pins.

19. The LED light reflecting device as claimed in claim 16, wherein the
collar-engaging member comprises a pair of styli, the pair of styli being
longitudinally spaced part and defining a space in which the annular ring
slides.

20. The LED light reflecting device as claimed in claim 5, wherein the
first and second actuators comprise: (a) a collar mounted around the
heatsink shaft, the collar comprising external threads and an inwardly
and radially extending annular member; (b) a collar-engaging member
comprising a proximal end attached to the reflector and a distal end
slidably engaged with the annular member; (c) a cup gear comprising
internal threads meshed with the external threads of the collar; and (d)
a motor for rotating the cup gear thereby driving the collar along the
heatsink shaft, moving the distal ends of the collar-engaging member
radially relative to the annular member, and rotating and tilting the
reflector simultaneously along a spiral path.

21. The LED light reflecting device as claimed in claim 20, wherein the
annular member is an inwardly facing and radially extending annular
groove.

22. The LED light reflecting device as claimed in claim 20, wherein the
annular member is an inwardly facing and radially extending annular ring.

23. The LED light reflecting device as claimed in claim 21, wherein the
collar-engaging member comprises a stylus, and the stylus comprises an
enlarged head movable within the annular groove.

24. The LED light reflecting device as claimed in claim 21, wherein the
collar-engaging member comprises a pair of coaxial pins.

25. The LED light reflecting device as claimed in claim 22, wherein the
collar-engaging member comprises a pair of styli, the pair of styli being
longitudinally spaced part and defining a space in which the annular ring
slides.

Description:

[0002] Many lighting devices have the function of reflecting ones beam
output to the particular direction the user desires. Many prior art
devices (e.g. stage lighting devices) move the light source and
reflective/refractive optics together. A common approach involves the use
of a pan motor to rotate the entire tilt assembly. The drawback of this
approach is bulkiness and it requires a large pan motor. Complicated slip
ring design has to be added in order to achieve continuous multiple pan
rotations because otherwise the wire supplying power to the tilt motor
will limit the pan rotation angle. As high power LED has overtaken
fluorescent lights in terms of efficacy (i.e. light flux output per unit
electrical power input), it is natural to use LED light source instead of
incandescent (very low efficacy) or compact fluorescent light source
(contains mercury). Since size of LEDs is much smaller as compared to
fluorescent lights giving same amount of light output, it is now possible
to implement light reflecting function within a small space such as a
light bulb. However, conventional approaches are not feasible because of
the unique characteristics of high power LEDs. One characteristic of high
power LED is that the heat generated during usage must be conducted away
in order to keep the junction temperature below its operating limit (e.g.
125 degree Celsius), or otherwise permanent degradation or even total
destruction will happen. The most common approach is by adding heatsink
function to the outer casing of the LED lighting device (such as a light
bulb) and keeping the thermal resistance between the LED and the heatsink
as low as possible. Unlike prior arts that use other types of light
sources, now there is a need for a new light reflecting mechanism such
that reflecting the light output from the LED (can be an array of LEDs)
does not require moving the LED at all. The reason is that it is
difficult to move the LED while keeping a good heat dissipation path
without moving the heatsink which is heavy in weight. Moving the bulky
heatsink is often not acceptable. For example, the lamp base of a light
bulb which fits into a lamp socket is the only mechanical mounting
available for a light bulb. The connection between a lamp base and a lamp
socket is rigid along the longitudinal direction but weak along the
horizontal direction. Moving heavy mass inside the light bulb will result
in swinging like a pendulum, resulting in the illuminated spot moving to
and fro which is unacceptable by user.

[0003] The above description of the background is provided to aid in
understanding a heat dissipating light reflecting device, but is not
admitted to describe or constitute pertinent prior art to the heat
dissipating light reflecting device disclosed in the present patent
application, or consider any cited documents as material to the
patentability of the claims of the present patent application.

SUMMARY

[0004] According to one aspect, there is provided a LED lamp with
adjustable beam direction. The lamp includes:

[0005] a housing;

[0006] a lamp base attached to one end of the housing for insertion into a
lamp socket;

[0007] a heatsink shaft mounted within the housing which serves as a
heatsink;

[0008] a high power LED attached to one end of the heatsink shaft;

[0009] a reflector having a light output front opening and an asymmetric
elliptical shaped rear opening, the LED being disposed proximate to the
rear opening;

[0010] a first actuator for rotating the reflector about the LED; and

[0011] a second actuator for tilting the reflector about the LED.

[0012] In one embodiment, the first actuator includes gear rotatable about
the heatsink shaft, two arms having two ends fixedly connected to the
gear and two opposite ends pivotably connected to a rear surface of the
reflector by two pivot joints respectively, and a pan motor for rotating
the gear and in turn rotating the reflector about a central longitudinal
axis of the heatsink shaft.

[0013] In one embodiment, the second actuator includes:

[0014] a collar mounted around the heatsink shaft and movable along two
columns connected to the housing and oriented parallel to the heatsink
shaft, the collar having external threads and an inwardly and radially
extending annular member;

[0015] a collar-engaging member having a proximal end attached to the
reflector and a distal end slidably engaged with the annular member;

[0016] a cup gear having internal threads meshed with the external threads
of the collar; and

[0017] a tilt motor for rotating the cup gear, thereby driving the collar
along the two columns, moving the distal end of the collar-engaging
member radially relative to the annular member, and tilting the reflector
about a pivot axis defined by the two pivot joints.

[0018] In one embodiment, the lamp further includes a power supply unit
for converting AC power to DC power, and an electronic control for
controlling the movement of the pan and tile motors.

[0019] In one embodiment, the first and second actuators are activated by
a remote control.

[0020] According to another aspect, there is provided a LED light
reflecting device including:

[0021] a housing;

[0022] a LED attached to the housing;

[0023] a reflector having a light output front opening and a rear opening,
the reflector being rotatably and tiltably coupled to the housing with
the LED disposed proximate to the rear opening;

[0024] a first actuator for rotating the reflector about the LED; and

[0025] a second actuator for tilting the reflector about the LED.

[0026] In one embodiment, the LED light reflecting device further includes
a heatsink shaft mounted within the housing, at least part of the housing
serving as a heatsink.

[0027] In one embodiment, the first actuator comprises a gear rotatable
about the heatsink shaft, two arms having two ends fixedly connected to
the gear and two opposite ends pivotably connected to a rear surface of
the reflector by two pivot joints, and a pan motor for rotating the gear
and in turn rotating the reflector about a central longitudinal axis of
the heatsink shaft.

[0028] In one embodiment, the second actuator includes:

[0029] a collar mounted around the heatsink shaft and movable along at
least one column connected to the housing and oriented parallel to the
heatsink shaft, the collar having external threads and an inwardly and
radially extending annular member;

[0030] a collar-engaging member having a proximal end attached to the
reflector and a distal end slidably engaged with the annular member;

[0031] a cup gear having internal threads meshed with the external threads
of the collar; and

[0032] a tilt motor for rotating the cup gear, thereby driving the collar
along the at least one column, and moving the distal end of the
collar-engaging member radially relative to the annular member, and
tilting the reflector about a pivot axis defined by the two pivot joints.

[0033] In one embodiment, the annular member is an inwardly facing and
radially extending annular groove.

[0034] In one embodiment, the collar-engaging member is a stylus comprises
an enlarged head movable within the annular groove.

[0035] In one embodiment, the collar-engaging member is a pair of coaxial
pins.

[0036] In one embodiment, the annular member is an inwardly facing and
radially extending annular ring.

[0037] In one embodiment, the collar-engaging member is a pair of styli.
The pair of styli is longitudinally spaced part and defining a space in
which the annular ring slides.

[0038] In one embodiment, the rear opening is asymmetric shaped.

[0039] In one embodiment, the rear opening is defined by a parabolic half
and a semi-circle half.

[0040] In one embodiment, the LED light reflecting device includes a
plurality of LEDs.

[0041] In one embodiment, the LED light reflecting device further includes
a plurality of sensors for sensing the pan and tilt motions of the
reflector.

[0042] In one embodiment, the LED light reflecting device further includes
a power supply unit for converting AC power to DC power, and an
electronic control for controlling the movement of the pan and tilt
motors.

[0043] In one embodiment, the two arms are spaced 180 degrees apart on the
reflector.

[0044] In one embodiment, the LED light reflecting device further includes
a link gear coupling between the motor and the gear rotating about the
heatsink shaft.

[0045] In one embodiment, the collar is mounted around the heatsink shaft
and movable along two columns connected to the housing.

[0046] In one embodiment, the LED is a high power LED.

[0047] In one embodiment, the reflector is a parabolic reflector.

[0048] In one embodiment, the reflector is an elliptical reflector.

[0049] In one embodiment, the reflector is a multi-facet reflector.

[0050] In one embodiment, the first and second actuators include:

[0051] a collar mounted around the heatsink shaft, the collar having
external threads and an inwardly and radially extending annular member;

[0052] a collar-engaging member having a proximal end attached to the
reflector and a distal end slidably engaged with the annular member;

[0053] a cup gear having internal threads meshed with the external threads
of the collar; and

[0054] a motor for rotating the cup gear thereby driving the collar along
the heatsink shaft, moving the distal ends of the collar-engaging member
radially relative to the annular member, and rotating and tilting the
reflector simultaneously along a spiral path.

[0055] In one embodiment, the annular member is an inwardly facing and
radially extending annular groove.

[0056] In one embodiment, the collar-engaging member is a stylus including
an enlarged head movable within the annular groove.

[0057] In one embodiment, the collar-engaging member is a pair of coaxial
pins.

[0058] In one embodiment, the annular member is an inwardly facing and
radially extending annular ring.

[0059] In one embodiment, the collar-engaging member is a pair of styli.
The pair of styli is longitudinally spaced part and defining a space in
which the annular ring slides.

[0060] Although the heat dissipating light reflecting device disclosed in
the present application is shown and described with respect to certain
embodiments, it is obvious that equivalents and modifications will occur
to others skilled in the art upon the reading and understanding of the
specification. The present application includes all such equivalents and
modifications, and is limited only by the scope of the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0061] Specific embodiments of the heat dissipating light reflecting
device disclosed in the present patent application will now be described
by way of example with reference to the accompanying drawings wherein:

[0062] FIG. 1 is a cross sectional view of a LED lamp with a heat
dissipating light reflecting device in accordance with an embodiment
disclosed in the present patent application;

[0063] FIG. 2 shows a reliable path to conduct heat from the high power
LED light source to the surrounding air;

[0064]FIG. 3 is an array of high power LEDs having lower temperature
difference between the junction and the LED PCB than that of a single LED
giving the same amount of light output;

[0065] FIGS. 4 and 5 show the pan motion mechanism;

[0066]FIG. 6 shows the relationship between tilt angle and vertical
displacement of the stylus;

[0067] FIGS. 7-9 show the stylus head of the reflector slidable within an
annular groove of the collar;

[0068] FIGS. 7(a), 8(a) and 9(a) show a pair of pins slidable within an
annular groove of the collar;

[0069] FIGS. 7(b), 8(b) and 9(b) show a pair of styli of the reflector
slidable relative to an annular ring of the collar;

[0070]FIG. 10 illustrates the tilt motion of a short focal length
reflector;

[0071]FIG. 11 illustrates the pan motion of a short focal length
reflector;

[0073] FIGS. 14 (a), 14(b), 14(c), 15(a), 15(b) and 15(c) show that a LED
light source mounted on a heatsink shaft achieve lower loss as compared
to a point light source mounted on a heatsink shaft whether there is no
opening at all or having an opening of either shape;

[0074] FIG. 16 shows how the LED light reflecting device illuminates a
light spot on the floor;

[0075] FIGS. 17 and 18 show how the LED light reflecting device generates
a spot ring on the floor;

[0076]FIG. 19 shows a second embodiment of the light reflecting device
with integrated cup and pan gears; and

[0077]FIG. 20 shows a spiral path of light from the light reflecting
device of FIG. 19.

DETAILED DESCRIPTION

[0078] Reference will now be made in detail to a preferred embodiment of
the heat dissipating light reflecting device disclosed in the present
patent application, examples of which are also provided in the following
description. Exemplary embodiments of the heat dissipating light
reflecting device disclosed in the present patent application are
described in detail, although it will be apparent to those skilled in the
relevant art that some features that are not particularly important to an
understanding of the heat dissipating light reflecting device may not be
shown for the sake of clarity.

[0079] Furthermore, it should be understood that the heat dissipating
light reflecting device disclosed in the present patent application is
not limited to the precise embodiments described below and that various
changes and modifications thereof may be effected by one skilled in the
art without departing from the spirit or scope of the appended claims.
For example, elements and/or features of different illustrative
embodiments may be combined with each other and/or substituted for each
other within the scope of this disclosure and appended claims.

[0080] FIG. 1 is a cross sectional view of a light-emitting diode (LED)
lamp 10 with a heat dissipating light reflecting device in accordance
with an embodiment disclosed in the present patent application. The LED
lamp 10 with adjustable beam direction may include a lamp base 12 that
may be configured for insertion into a conventional lamp base holder or
socket. The lamp base 12 is attached to a housing 14. A heatsink 16,
including a heatsink shaft 18, is mounted within the housing 14 for heat
dissipation. A LED 20 may be attached to one end of the heatsink shaft
18. The heat dissipating path of the LED lamp 10 is illustrated by the
arrows in FIG. 2. An array of LEDs 20 may be attached to the end of the
heatsink shaft 18 to produce a higher power LED light effect, as depicted
in FIG. 3. The LEDs have lower temperature difference between the
junction and the LED PCB than that of a single LED giving the same amount
of light output.

[0081] The embodiment shown in FIG. 1 is a PAR38 sized light bulb or lamp.
It draws electric power from an ordinary E26 (used in US) or E27 (used in
Europe) lamp base holder or socket. Using Seoul Semiconductor's 10 watt
class white LED, the lamp can deliver 700-900 lumens. Using Osram's Oslon
white LED, the lamp can deliver over 2,000 lumens. Installation can be
completed within seconds and an electrician is not required to perform
the installation. When a user wants to change the light direction, he can
send a command to the control electronics via wireless (i.e. RF or
infrared) or wired (i.e. power line communication technology) link. He
can command the device to illuminate at a new direction or to move to a
previously stored direction. For example, in a department store, certain
area is rearranged during every weekend to display certain promotion
items. The directions of the conventional spot lights are required to be
adjusted and re-adjusted manually by climbing up a ladder or standing on
a chair twice before and after the weekend. By replacing the conventional
spot lights with this PAR38 lamp and without any electrical wiring and
installation work, the direction of the light beam can be re-adjusted
manually (via remote control) or by commanding all PAR38 lamps in that
area to change to various stored directions at the press of a button. In
many homes, lighting fixtures were installed long time ago. The location
of the lighting fixtures may not match the new furniture or the changing
needs of the occupants. Sometimes we need certain area to be better lit
up. Although some lighting fixtures can have the beam direction
adjustable, such adjustments are inappropriate to be done by children or
elderly people. Even ordinary people may need to stand on a chair or
climb up a ladder in order to adjust the beam direction. The PAR38 lamp
of the present application solves this problem and makes changing
illumination conditions as easy as changing a TV channel.

[0082] The LED lamp 10 includes an elliptical or parabolic reflector 30.
The reflector 30 has a light output front opening 32 and a rear opening
34. The LED 20 is disposed proximate to the rear opening 34 of the
reflector 30. The rear opening 34 may be asymmetric elliptical in shape.
According to the illustrated embodiment, the rear opening 34 can be
formed by a semi-circular half 33 and a parabolic half 35.

[0083] The lamp 10 includes a first actuator for rotating the reflector 30
about the LED 20, and a second actuator for tilting the reflector 30
about the LED 20.

[0084] As shown in FIGS. 4 and 5, the first actuator may include a pan
gear 40 mounted on a gear mount 47 and rotatable about the heatsink shaft
18. The pan gear 40 and the reflector 30 may be connected together by two
arms 42, 44. A pan motor 46 is employed to rotate the gear 40, directly
or via an intermediate link gear 48, which in turn rotate the reflector
30.

[0085] The pan motor 46 drives the pan gear 40 via the link gear 48. The
link gear 48 can be employed for keeping the overall height of the whole
moving mechanism low. The pan motor 46 can be mounted on the other side
of the heatsink base so as to drive the pan gear 40 directly without
using the link gear 48. Each of the actuating arms 42, 44 has one end
forming a pivot joint 43, 45 with the reflector 30 while having the other
end fixed on the pan gear 40. The reflector's pan rotation is capable of
running in the same direction endlessly (i.e. multiple numbers of
rotations) without stopping to scan and illuminate a large size spot or
spot ring on a plane orthogonal to the central longitudinal axis X of the
lighting device. The two actuating arms 42, 44 rotate with the pan gear
40 together about the heatsink shaft 18, which acts as a rotation shaft
of the pan gear 40.

[0086] As shown in FIGS. 7-9, the second actuator may include a collar 50
mounted around the shaft 18 and movable along one or more columns 52, 53
parallel to the shaft 18. The collar 50 has external threads 54 and an
inwardly facing and radially extending annular groove 56. A stylus 58 has
a proximal end attached to the reflector 30 and a distal end, in the form
of an enlarged head 59, disposed within the annular groove 56. A cup gear
60 has internal threads 62 meshed with the external threads 54 of the
collar 30. A tilt motor 64 is employed to rotate the cup gear 60 about
the axis X, drive the collar 50 to move up or down along the columns 52,
53 and move the distal end of the stylus 58 generally inwardly or
outwardly and radially within the annular groove 56 thereby tilting the
reflector 30.

[0087] Two other embodiments of the engagement of the reflector 30 with
the collar 50 are illustrated in FIGS. 7(a)-9(a) and FIGS. 7(b)-9(b)
respectively.

[0088] As shown in FIGS. 7(a)-9(a), the collar 50' may have an inwardly
facing and radially extending annular groove 56'. A pair of coaxial pins
58' has proximal ends attached to the reflector 30 and distal ends
slidably engaged within the annular groove 56'. The tilt motor 64 is
employed to rotate the cup gear 60, drive the collar 50' to move up or
down along the columns 52, 53, and move the distal ends of the pair of
pins 58' generally inwardly or outwardly and radially within the annular
groove 56' thereby tilting the reflector 30.

[0089] As shown in FIGS. 7(b)-9(b), the collar 50'' may have an inwardly
facing and radially extending annular ring 56''. A pair of styli 58'' has
proximal ends attached to the reflector 30 and distal ends slidably
engaged with the annular ring 56''. The pair of styli 58'' is
longitudinally spaced apart defining a space in which the annular ring
56'' slides. The tilt motor 64 is employed to rotate the cup gear 60,
drive the collar 50'' to move up or down along the columns 52, 53, and
move the distal ends of the pair of pins 58' generally inwardly or
outwardly and radially relative to the annular ring 56' thereby tilting
the reflector 30.

[0090] Tilt angle can be changed by varying the position of the reflector
stylus 58 which forms a hinge with the two pivot joints 43, 45 of the
reflector 30. The tilt motor 64 drives the cup gear 60 which contains
helical threads 62 on the internal wall. The collar 50 has a tendency of
rotating with the cup gear 60. Due to the restriction effect of the
columns 52, 53 the collar 50 can only translates inwards or outwards
without rotation. Tilt motion components (i.e. cup gear 60, collar 50,
tilt motor 64) are mounted onto the stationary housing 14, rather than
mounted on a chassis moved during pan motion, as in most prior art. The
collar 50 may be formed of two layers defining two contacting surfaces.
The stylus head 59 can move between the two contacting surfaces. The tilt
motion components do not load the pan motor 46 because of the stylus'
sliding motion over the smooth surfaces of the double layer collar 50. In
other words, the light reflecting component's tilt and pan motions are
driven independently.

[0091] As shown in FIGS. 10 and 11, the reflector 30 is pivotable about a
pivot axis Y defined by two 180 degrees apart cylindrical holes 31, 37
located at its base, such that the focal point F remains at the same
center position between the two pivot arms 42, 44 all the time. The
stationary high power LED 20 is located at the base of the reflector 30
and remains at the reflector's focal point F during all reflector's tilt
and pan motions. The reflector's asymmetrical elliptical rear opening 34
at its base allows tilting at a large angle about the stationary high
power LED 20 with only small light loss, while maintaining a reliable
thermal path from the LED 20 to the heatsink 16.

[0092] The parabolic or elliptical reflector 30 is a short focal length
reflector capable of rotating generally coaxially about the stationary
high power LED 20 with small space consumption to reflect the LED light
to the desired direction. The reflector 30 with short focal length,
including multi-facet designs, has a smaller diameter light output
opening than another one of the same height but with longer focal length.
In other words, a short focal length reflector consumes less space
(including space consumed for its rotation) and is lighter in weight
(smaller angular momentum), reducing the impact due to pendulum effect.
It also helps to shorten the length of the heatsink shaft 18 and lower
its thermal resistance.

[0094] FIGS. 14 (a), 14(b), 14(c), 15(a), 15(b) and 15(c) and Table 1 show
that a LED light source mounted on a heatsink shaft achieve lower loss as
compared to a point light source mounted on a heatsink shaft whether
there is no opening at all or having an opening of either shape. A
reflector having asymmetrical elliptical opening gives lowest light loss
as compared to reflectors having other types of openings. FIG. 14 (a)
shows the reflector at Angle=0 with an asymmetrical elliptical rear
opening; FIG. 14 (b) shows the reflector at Angle=0 with a symmetrical
elliptical rear opening; FIG. 14 (c) shows the reflector at Angle=0 with
a circular rear opening; FIG. 15 (a) shows the reflector at Angle=60 with
an asymmetrical elliptical rear opening; FIG. 15 (b) shows the reflector
at Angle=60 with a symmetrical elliptical rear opening; and FIG. 15 (c)
shows the reflector at Angle=60 with a circular rear opening.

[0095] Conventional point light source gives a low optical efficiency
because light radiation going to the heatsink direction is lost. If we
move the point light source towards the centre of the reflector, then we
can get higher optical efficiency. With a longer focal length, a
parabolic or elliptical reflector having same height will have larger
diameter. FIGS. 12 and 13 show that changing the focal length from 5 mm
to 20 mm result in a 129 mm diameter reflector. In order to allow the
reflector to rotate to maximum 60 degrees in opposite directions from
normal, a 20 mm focal length reflector consumes 1,463 cc space while a 5
mm focal length reflector only consumes 551 cc space.

[0096] FIG. 16 shows how the LED light reflecting device illuminates a
light spot S on the floor.

[0097] FIGS. 17 and 18 show how the LED light reflecting device generates
a spot ring R on the floor.

[0098]FIG. 19 shows a second embodiment of the light reflecting device
with integrated pan and cup gear 60. The mechanism of the second
embodiment is the same as that of the first embodiment except that the
cup gear for tilt motion is integrally formed with the pan gear for pan
motion. Only one motor 64 is used to rotate the integrated pan and cup
gear 60 thereby rotating and tilting the reflector 30 simultaneously
along a spiral path, as illustrated in FIG. 20.

[0099] If a light source is mounted onto a heatsink shaft, an LED light
source (generally all LEDs have Lambertian characteristics) achieves much
lower loss as compared to conventional point light source. Such
phenomenon is confirmed using a simulation exercise. Light sources of
both types are mounted on 14 mm diameter copper rods. A 50 mm diameter
parabolic reflector has an asymmetrical elliptical opening at the base to
allow the tilt rotation of the reflector. Two less preferred designs are
also shown for comparison: (1) symmetrical elliptical opening and (2)
circular opening. Symmetrical elliptical opening allows the reflector to
rotate in opposite tilt directions while circular opening allows tilting
in all directions.

[0100] A point light source and a Seoul Semiconductor model P7 LED (11
Watts) having the same light flux output are used to simulate the
reflected light output from various designs. The simulations were
conducted using a ray tracing software called Tracepro. At zero degree
tilt angle, the reflector outputs 390 lumens using an LED light source
whereas it only gives 217 lumens if point light source of same light
output is used. The reason for the difference is because about half of
the point light source radiation goes to the back direction whereas all
the LED light output goes to the front direction. Point light source also
gives low output when the reflector is tilted.

[0101] Thermal interface material should be used to lower the thermal
resistance between the heat conducting components such as the LED PCB and
the heatsink shaft 18. A very reliable heat conduction path, as shown by
the arrows in FIG. 2, can be guaranteed because there is no moving part
between the LED heat source 20 and the heatsink 16.

[0102] The LED lamp 10 further includes a power supply and electronic
control 22 coupled to the LED 20 and the first and second actuators, as
depicted in FIG. 1. The power supply and electronic control 22 includes a
power supply unit and an electronic control.

[0103] The power supply unit converts the high voltage AC power to low
voltage DC power for use by the high power LED 20 and the control
electronics. During the first use after installation, the control
electronics recognize the pan zero position and tilt zero position by
reading the inputs of sensor 41. Whenever the control electronics receive
a new command to move the beam to a new direction, it outputs the
appropriate power to the pan motor 46 and tilt motor 64 while reading the
current angle data from the sensors.

[0105] According to the requirements on optical effects of the heat
dissipating light reflecting device, the short focal length reflector
disclosed in the present patent application can be manufactured by a
method including the steps of (A) selecting the LED light source; and (B)
Designing the short focal length reflector. Details of the above steps
will be described hereinbelow.

[0106] A. Selecting the LED Light Source

[0107] There are many design options in selecting the LED light source.
Both a single high power LED and an array of LEDs can deliver an equal
amount of light flux. For example, the body of a Seoul Semiconductor's P7
LED (10 watt class) is 12 mm in diameter with a thermal resistance of 3
degrees Celsius per watt; whereas Osram's Oslon series LED (1 watt class
but can operate up to 3 watts) is only 3 mm by 3 mm in size with a
thermal resistance of 7 degrees Celsius per watt. 9 pieces of Oslon LED
occupies similar space as P7 but the temperature difference between an
Oslon's LED junction and its solder terminal is only 7 degrees Celsius,
where as the P7 temperature difference is 30 degrees. In other words, LED
array design requires a smaller heatsink to maintain same LED junction
temperature. The choice of LED will determine the size of the reflector
asymmetrical opening.

[0108] B. Designing the Short Focal Length Reflector

[0109] The relationship of the focal length, diameter and height of the
reflector generally follow a parabolic or elliptical function. Such
relationship is also valid for multi-facet reflectors. The reflector's
inside optical surface can be designed with a commercial software package
in order to achieve the desired beam characteristics. As shown in FIGS.
12 and 13, the maximum tilt angle of the reflector will determine the
space requirement of the reflector's motion. Since the total available
space of a light bulb is limited, the maximum tilt angle is normally
decided with consideration on the space requirements of its heatsink,
motion components, control and power electronics. FIG. 6 shows the
relationship between tilt angle and vertical displacement of the stylus;

[0110] The tilt angle of the reflector is given by the following
relationship:

Tilt angle=arcsine(vertical displacement/distance between stylus head
center and the pivot axis)-offset, where as

Offset=arcsine(vertical distance between the pivot axis and the stylus
head center/distance between stylus head center and the pivot axis)

[0111] Thus the maximum vertical displacement is given by:

Maximum vertical displacement=sine(maximum tilt angle+offset)*distance
between stylus head center and the pivot axis

[0112] While the heat dissipating light reflecting device disclosed in the
present application has been shown and described with particular
references to a number of preferred embodiments thereof, it should be
noted that various other changes or modifications may be made without
departing from the scope of the appending claims.